Everlast PowerTig 210EXT maximum AC output amp

[Ultraman]

Ok, I just bought the digital 210EXT and I am finding out that maximum amps in AC is only about 150 even though the digital readout says 210. I have a clamp meter (Extech 623) and this is what I got:

10amps .. 10.2measured
30amps .. 26.9
50amps .. 44.1
70amps .. 57.9
90amps .. 71.0
110amps .. 85.1
130amps .. 98.9
150amps .. 112.9
170amps .. 126.7
190amps .. 140.9
210amps .. 154.7

wall outlet: 240V
AC freq: 150Hz
AC balance: -30% (80%EN)
wave form: adv. square
pulse: off
electrode: 1.5% lanthanated (3/32" 2.4mm)
argon: 15cfm (victor regulator)

Hidden menu setting:
D02: 0.5sec
D03: 100Hz
D05: 40amps

I put the torch on a fixed clamp with arc gap of about 1/16". I tried torch switch and foot pedal with similar results. At maximum, I can barely start the puddle on a 1/4" AL plate. Is there more settings inside the machine I need to check?

What is going on??? On DC, maximum amp I measured was 201.0 so It's close enough.

[Rambozo]

Ok, I just bought the digital 210EXT and I am finding out that maximum amps in AC is only about 150 even though the digital readout says 210. I have a clamp meter (Extech 623) and this is what I got:

10amps .. 10.2measured
30amps .. 26.9
50amps .. 44.1
70amps .. 57.9
90amps .. 71.0
110amps .. 85.1
130amps .. 98.9
150amps .. 112.9
170amps .. 126.7
190amps .. 140.9
210amps .. 154.7

wall outlet: 240V
AC freq: 150Hz
AC balance: -30% (80%EN)
wave form: adv. square
pulse: off
electrode: 1.5% lanthanated (3/32" 2.4mm)
argon: 15cfm (victor regulator)

Hidden menu setting:
D02: 0.5sec
D03: 100Hz
D05: 40amps

I put the torch on a fixed clamp with arc gap of about 1/16". I tried torch switch and foot pedal with similar results. At maximum, I can barely start the puddle on a 1/4" AL plate. Is there more settings inside the machine I need to check?

What is going on??? On DC, maximum amp I measured was 201.0 so It's close enough.

Because that meter is a true RMS meter, you will probably have to run 50% balance to get accurate average current readings. Also you might have to lower the frequency depending on the specs of the meter, a lot of them are calibrated to read properly only around 60 Hz. I have that problem with VFD's all the time. Dial back to 60 Hz and 50% balance and try the clamp meter then. You might also see what happens with the different wave forms. The fact that it reads right on DC tells me all the power components are doing their job.

Without preheat or He, 1/4" plate is near the max of that machine. It might take a little while to get the puddle going, but it should have no problem in maintaining it, at 80%EN. If it can't, then something is wrong.

[everlastsupport]

I would not try any testing unless it was at 50-60Hz.

[performance]

You also should get an exact reading on your wall outlet. (input) Odds are it isn't exactly 240.

[Kempy]

This is a lot of good information if a person does not think their welder is not up to snuff and how to test it.

[Ultraman]

Alright, ran the test again per Rambozo's suggestion. (balled up a lot of tungsten lol)

outlet voltage: 118.5/118.7/237.1
AC freq: 60Hz
AC balance: 0% (50% EN)
everything else same...

10amps .. 10.4measured
30amps .. 29.5
50amps .. 48.9
70amps .. 65.2
90amps .. 81.6
110amps .. 97.3
130amps .. 114.7
150amps .. 130.1
170amps .. 146.7
190amps .. 165.6
210amps .. 182.7

Better results but it's difficult to get quality welds at these settings IMO. Changing wave form to soft sq, I got 157.8amps at 210 setting, on sine wave, I got 121.8amps...

Changing AC balance to -20% (70% EN) on adv. sq wave, which is more weldable for me, I got 167.1amps at 210.

I really thought I could weld 1/4" plate with this machine... Oh well.

[performance]

How are you testing it, exactly? Will send a note to the factory, but have to have as much detail as possible to verify issue.

[Kempy]

I just tried my welder on 1/4 alum. plate did not clean just set to 210 amps and 170 amps it weld just fine see pic. I used a 210EXT at Everlast CA as a test and it welded 1/4 plate just fine something must be set wrong I have see the wires from the electric box have the wires wrong and different voltages and not a good ground or common not grounded right.

Alright, ran the test again per Rambozo's suggestion. (balled up a lot of tungsten lol)

outlet voltage: 118.5/118.7/237.1
AC freq: 60Hz
AC balance: 0% (50% EN)
everything else same...

10amps .. 10.4measured
30amps .. 29.5
50amps .. 48.9
70amps .. 65.2
90amps .. 81.6
110amps .. 97.3
130amps .. 114.7
150amps .. 130.1
170amps .. 146.7
190amps .. 165.6
210amps .. 182.7

Better results but it's difficult to get quality welds at these settings IMO. Changing wave form to soft sq, I got 157.8amps at 210 setting, on sine wave, I got 121.8amps...

Changing AC balance to -20% (70% EN) on adv. sq wave, which is more weldable for me, I got 167.1amps at 210.

I really thought I could weld 1/4" plate with this machine... Oh well.

[cbmkr]

Had a similar situation several years ago with a machine in the plant it would not give the same results as other machines with the same settings. We did a bunch of voltage and amp testing on the machine checked some parts and replaced some and could not get a good handle on what was going on. We ended up finding a connection in a twist lock connector on the incoming power that was not tight. We could test it and get the correct rated power by testing it at the plug. We finally found the problem testing the incoming voltage when the machine was under a load and had a voltage drop on one leg of the incoming power. Tightened the connection and everything worked as it should. Sometimes it is just simple stuff that makes things not work right.

This may or may not be your problem but thought this might be something to try.

[5440]

For a quick and dirty test, measure the current inut and check it against the rated value.

I did this for my Synchrowave 180SD for something to do once. I set the min/max on the the Fluke and got current values that were almost bang on. Of course a transformer based TIG will not have the harmonics that an inverter machine throughs off, but may be worth a check.